Bunching resistant absorbent article

ABSTRACT

An absorbent article, such as a pantiliner, is provided having excellent resistance to bunching. The absorbent article exhibits a Bunching Resistance in the range of about 205 g to 450 g and may be formed with an absorbent core comprising at least two absorbent layers having different Gurley Stiffnesses.

This application is a divisional of parent application Ser. No.09/348,956, filed Jul. 7, 1999, now U.S. Pat. No. 6,565,547, priority ofwhich is hereby claimed.

The present invention relates to an absorbent article having excellentresistance to bunching. The absorbent article exhibits a BunchingResistance in the range of about 205 g to about 450 g and may be formedwith an absorbent core comprising at least two absorbent layers havingdifferent Gurley Stiffnesses.

BACKGROUND OF THE INVENTION

An absorbent article such as a sanitary napkin, pantiliner, diaper,incontinence pad, or inter labial article typically comprises a liquidpermeable cover on its body facing side, a barrier on its garment facingside, and an absorbent core in between. A common problem with absorbentarticles is bunching and deformation of the article due to movement ofthe person wearing it. Bunching and deformation in turn impair theability of the article to absorb exudates from the body.

Several suggestions for solving the problem of bunching have been made.For example, U.S. Pat. No. 4,886,513 to Mason, Jr. et al. discloses apad comprising a flexibly stiff reinforcing member to maintain the pad'sshape. The reinforcing member may be for example a strip of polyethyleneextending around the periphery of the pad.

U.S. Pat. No. 5,609,588 to DiPalma et al. and U.S. Pat. No. 5,803,920 toGilman et al. relate to the use of a resilient layer of non-absorbentfoam in a sanitary napkin. The resilient layer is said to resistbunching during use of the napkin, so that the napkin has reducedtwisting and bunching.

U.S. Pat. No. 5,387,208 to Ashton et al. discloses an absorbent articlewith an absorbent core having improved integrity by virtue of thepresence of a primary core integrity layer. The primary core integritylayer is made of a liquid impervious mesh of thermoplastic material,preferably a hot melt adhesive.

U.S. Pat. No. 4,973,325 to Sherrod et al. relates to an absorbentarticle having a transfer member positioned between two side-by-sideabsorbents. The transfer member is said to allow the absorbent articleto flex in the middle and conform to the body of the wearer, therebyreducing bunching.

U.S. Pat. No. 5,575,786 to Osborn recites in claim 1 a sanitary napkincomprising absorbent portions aligned along the longitudinal centerlineof the napkin and peripheral portions aligned adjacent to the absorbentportions. The peripheral portions have a different stiffness than theabsorbent portions, and the difference in stiffness is claimed tosubstantially prevent bunching of the napkin when the napkin issubjected to lateral stresses.

Despite these attempts at maintaining the physical integrity ofabsorbent articles, an absorbent article having even betteranti-bunching properties is needed. Applicants have identified a classof such absorbent articles. Specifically, the present invention providesan absorbent article, such as a sanitary napkin, pantiliner, diaper,incontinence pad, or an interlabial article, in particular a thinabsorbent article, comprising in sequence a liquid permeable cover, anabsorbent core, and a barrier, having a caliper of less than 0.2 inches,a length of less than about 8 inches, a width of less than about 4inches, and a Bunching Resistance of at least about 205 g. Preferably,the absorbent article comprises an absorbent core comprising at leasttwo absorbent layers having different Gurley Stiffnesses.

SUMMARY OF THE INVENTION

The present invention provides an absorbent article comprising insequence a liquid permeable cover, an absorbent core, and a barrier,wherein the absorbent article has a caliper of less than about 0.2inches, a length of less than about 8 inches, a width of less than about4 inches, and exhibits a Bunching Resistance of about 205 g to about 450g.

The present invention further provides an absorbent article comprisingin sequence a liquid permeable cover, an absorbent core comprising atleast two absorbent layers having different Gurley Stiffnesses, and abarrier.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a pantiliner according to the invention.

FIG. 2 depicts the apparatus used for the Curved Longitudinal BendingTest.

DETAILED DESCRIPTION OF THE INVENTION

The absorbent article may for example be a sanitary napkin, apantiliner, a diaper, incontinence pad, inter labial article, or othersimilar product for absorbing exudates from the body, such as menses,urine, and feces. Preferably, the absorbent article is a sanitary napkinor a pantiliner. Such sanitary napkin or pantiliner may have anapproximately rectangular, oval, dogbone, or peanut shape. The absorbentarticle is thin, i.e., having a caliper of less than about 5 mm.Preferably, the caliper of the absorbent article is less than about 3mm, more preferably less than about 2.5 mm. The absorbent article has alength of less than about 8 inches, preferably 7 inches, and a width ofless than about 4 inches, preferably less than about 3 inches.

FIG. 1 depicts a pantiliner according to the invention, and is used forpurposes of illustration in the following description of the invention.The pantiliner shown in FIG. 1 comprises in sequence from itsbody-facing side 1 to its garment-facing side 2 a liquid permeable cover3, an absorbent core 4, and a barrier 5. The liquid permeable cover 3 ofthe absorbent article may be formed from any fluid pervious materialthat is comfortable against the skin and that permits fluid to penetrateto the absorbent core, which retains the fluid. A variety of materialsare known for this purpose, and any of these may be used. The covershould retain little or no fluid in its structure to provide arelatively dry surface next to the skin. The cover may be a fibrousnon-woven fabric made of fibers or filaments of polymers such aspolyethylene, polypropylene, polyester, or cellulose. Alternatively, thecover may be formed from an apertured polymeric film. The thickness ofthe cover may vary from approximately 0.001 to 0.062 inch, depending onthe material chosen. Generally, the liquid permeable cover 3 is a singlesheet of material having a width sufficient to cover the body-facingside 1 of the article.

The absorbent article further comprises a barrier 5 on its garmentfacing side 2. The barrier is typically liquid impermeable and maycomprise any thin, flexible, material such as a polymeric film, forexample, polyethylene, polypropylene, or cellophane. Alternatively, thebarrier may be a normally fluid permeable material that has been treatedto be impermeable, such as impregnated fluid repellent paper ornon-woven fabric material, or a flexible foam, such as polyurethane orcross-linked polyethylene. If higher Bunching Resistance is desired, afoam, particularly a closed cell foam, may be used as the barrier. Thebarrier may be a single or multilayer structure, and may also be“breathable,” that is liquid impermeable and vapor permeable. Thethickness of the barrier when formed from a polymeric film typically isabout 0.0005 to 0.002 inch. A variety of materials are known in the artfor use as barriers, and any of these may be used.

Generally, the barrier 5 has a width sufficient to cover thegarment-facing side 2 of the absorbent article. The barrier may extendaround the sides of the absorbent core in a C-shaped configuration withthe portions of the barrier that are adjacent its longitudinal edgesextending upwardly from the garment facing side toward the body facingside of the article.

The absorbent core 4 comprises at least one absorbent layer 6. In apreferred embodiment of the invention, the absorbent core comprises atleast two absorbent layers having different Gurley Stiffnesses. GurleyStiffness is measured by TAPPI T543 om-94.

For example, the absorbent core may comprise two absorbent layers, onehaving a high Gurley Stiffness, i.e., greater than about 100, preferablygreater than about 120, more preferably greater than about 150,milligrams, and one having a low Gurley Stiffness, i.e., less than about50, preferably less than about 40, more preferably less than about 35,milligrams. When two absorbent layers are employed, the first absorbentlayer proximal the liquid permeable cover has a low Gurley Stiffness,i.e., less than about 50 milligrams, and the second absorbent layerproximal the barrier has a high Gurley Stiffness, i.e., greater thanabout 100 milligrams.

Alternatively, the absorbent core may comprise three absorbent layerswith alternating Gurley Stiffnesses: high/low/high or low/high/low.Similarly, the absorbent core may comprise four or more absorbent layerswith alternating high and low Gurley Stiffnesses, as desired.

In another embodiment, the absorbent core comprises a single absorbentlayer having zones with different Gurley Stiffnesses. Such zones mayresult in Gurley Stiffness variations along the length, width, orthickness, or combinations of these, of the absorbent layer.

Construction of an absorbent core comprising absorbent layers ofdiffering Gurley Stiffnesses advantageously provides the absorbentarticle with stiffness and flexibility simultaneously. The high GurleyStiffness layer provides rigidity and stability, while the low GurleyStiffness layer provides flexibility and suppleness. The total effect ofthis combined structure results in an absorbent article having superioranti-bunching properties as well as flexibility.

One particularly useful absorbent core comprises two absorbent layers ofthermobond airlaid fibrous web with one or more superabsorbent polymersin between. The first absorbent layer proximal the body facing side ofthe article comprises about 50 to 65% pulp, the remainder being acombination of polyethylene/polypropylene bicomponent fibers andpolyethylene/polyester bicomponent fibers, and has a Gurley Stiffness inthe range of about 20 to about 50, preferably about 25 to about 35,milligrams. The second absorbent layer proximal the garment facing sideof the article comprises less than about 50% pulp, the remainder being acombination of polyethylene/polypropylene bicomponent fibers andpolyethylene/polyester bicomponent fibers, and has a Gurley Stiffness ofabout 100 to about 200, preferably about 135 to about 175, milligrams.

The absorbent article may be applied to the crotch of underpants byplacing the garment facing side of the absorbent article against theinside surface of the crotch of the underpants. Strips of pressuresensitive adhesive 7 may be applied to the garment facing side 2 of theabsorbent article to help maintain it in place. As used herein, the term“pressure-sensitive adhesive” refers to any releasable adhesive orreleasable tenacious means. Suitable pressure sensitive adhesivesinclude for example water-based adhesives such as acrylate adhesives.Alternatively, the adhesive may comprise rapid setting thermoplastic“hot melt” rubber adhesives or two-sided adhesive tape.

A paper release strip 8 that has been coated on one side, may be appliedto protect the strips of adhesive 7 prior to use. The coating, forexample silicone, reduces adherence of the coated side of the releasestrip to the adhesive. The release strip can be formed from any suitablesheet-like material which, when coated, adheres with sufficient tenacityto the adhesive to remain in place prior to use but can be readilyremoved when the absorbent article is to be used.

The absorbent article may comprise other known materials and layers,such as transfer layers, foam layers, odor control agents, constructionadhesives, all of which are known in the art. The absorbent article canoptionally be embossed with decorative designs using conventionaltechniques.

The absorbent core may optionally contain superabsorbent polymers,either in one of more absorbent layers, or preferably in between theabsorbent layers. Superabsorbent polymers are used to increase theliquid management properties of absorbent articles, such as capacity andretention of fluids. The amount of superabsorbent polymer contained bythe absorbent article may range from about 0.1 to about 5 grams,preferably from about 0.2 to about 2.5 grams, more preferably from about0.3 to about 1 grams.

The absorbent article has a Bunching Resistance of about 205 to about450 g, preferably about 250 to about 360 g. Bunching Resistance ismeasured by the Curved Longitudinal Bending Test, which is carried outon an anatomically shaped apparatus as shown in FIG. 2. The apparatuscomprises two smooth, convex, stainless steel plates 50 placed at a 40degree angle from one another to form a v-shaped trough 51. The widestdistance (at the top) between the plates 52 is 73 mm and the narrowestdistance (at the bottom) 53 is 18 mm. A vertically movable, curved padholder 54 is supported by a shaft 55 and centered between the plates 50.The shaft 55 is connected to a tensionmeter 56. The holder 54 is placedperpendicular to the horizontal axis of the two plates 50. Thetensionmeter 56 measures the compression force needed to deform a samplelengthwise in the narrow gap 53 of 18 mm. The tensionmeter is initiallyset at 50 kg. The shaft speed is set at 50.0 centimeters per minute perfull stroke length. Any release paper is removed from the absorbentarticle prior to placement in the apparatus, and talc powder is appliedto exposed positioning adhesive to provide a tackless surface. Thearticle is placed, with cover facing down and the barrier facing up, inthe holder 54, and the shaft 55 is actuated. The peak loads are measuredfor 5 cycles. Values are reported as peak Load 1, peak load 5, and %drop between load 1 and load 5.

The Bunching Resistance of the present absorbent article is very high,higher than that of known absorbent articles of similar thickness. Thelow level of bunching experienced with these products provides a morecomfortable body facing surface against the skin and avoids theformation of channels that encourage the fluid to flow laterally out ofthe absorbent article.

The following non-limiting examples further illustrate the invention.

EXAMPLES 1–15 AND A–II

A series of pantiliners having thicknesses in the range of 0.06 to 0.2inches were subjected to the Curved Longitudinal Bending Test using theapparatus shown in FIG. 2. Examples A–II were commercially availablepantiliners, while Examples 1–15 were pantiliners of the invention.

Specifically, the pantiliners of Examples 1–15 comprised a liquidpermeable cover, an absorbent core comprising two absorbent layers, anda barrier. The absorbent layer adjacent the liquid permeable cover wasmade of about 50 to 65% pulp, the remainder being a combination ofpolyethylene/polypropylene bicomponent fibers and polyethylene/polyesterbicomponent fibers. The absorbent layer adjacent the barrier was made ofless than about 50% pulp, the remainder being a combination ofpolyethylene/polypropylene bicomponent fibers and polyethylene/polyesterbicomponent fibers. It should be noted that the pantiliners of Examples6–10 were handmade samples.

The results are given in the Tables.

TABLE 1 Invention Example Bend Resistance [g] 1 298.1 2 293 3 296.1 4246.4 5 271 Mean: 280.92 6 186 7 165.1 8 175.6 9 183.3 10  166.8 Mean:175.36 11  259.3 12  238.4 13  243.4 14  261.5 15  231 Mean: 246.72

TABLE 2 ALWAYS ALLDAYS* Example Bend Resistance [g] A 198.4 B 196.3 C173.9 D 170.5 E 201.4 Mean: 188.1

TABLE 3 ALLDAYS Light* Example Bend Resistance [g] F 197.2 G 192.1 H190.9 I 204 J 192 Mean: 195.24

TABLE 4 KOTEX Lightdays** Example Bend Resistance [g] K 102.0 L 104.7 M98.9 N 101.9 O 82.1 P 75.4 Q 85.1 R 94.3 S 88.1 T 101.5 Mean: 93.4

TABLE 5 CAREFREE To Go*** Example Bend Resistance [g] U 55.1 V 49.3 W39.5 X 45.7 Y 39.2 Z 49.3 AA 46.3 BB 53.1 CC 36.8 DD 41.4 EE 43.2 FF44.3 GG 48.9 HH 38.8 II 42.1 Mean: 44.9 *Commercially available fromProcter & Gamble Company. **Commercially available from Kimberly ClarkCorp. ***Commercially available from Personal Products Worldwide, adivision of McNeil-PPC, Inc.

EXAMPLES 16–35

Ten, two layer absorbent cores of the same type used in the pantilinersof Examples 1–15 were tested for Gurley Stiffness as follows. In eachcase, the two absorbent layers were separated from each other, and theGurley Stiffness of each layer was measured according to by TAPPI T543om-94. The results are shown in Table 6 and 7. Examples 16–25 were theabsorbent layers proximal the covers of the pantiliners (5 g weight inthe 2 inch position, factor 11.1). Examples 26–35 were the absorbentlayers proximal the barriers of the pantiliners (25 g weight in the 2inch position, factor 55.6).

TABLE 6 Gurley Stiffness Example Milligrams 16 36.075 17 24.975 1831.635 19 30.525 20 28.86 21 35.52 22 40.515 23 25.53 24 27.195 2530.525 Average 31.14

TABLE 7 Gurley Stiffness Example Milligrams 26 155.68 27 183.48 28155.68 29 169.58 30 144.56 31 177.92 32 183.48 33 150.12 34 177.92 35166.8 Average 166.52

EXAMPLE 37

Several commercially available pantiliners and two having the sameconstruction as the pantiliners of Examples 1–15 were tested for comfortwith groups of consumers. The consumers were asked to use thepantiliners and rate them on a scale of 1 to 10 for comfort to wear. Theresults are given in Table 8.

TABLE 8 Comfort Average Rating for Comfort to Number of Product Wear(0–-10) Women Kao* 7.5 104 KOTEX Lightdays* 7.6 140 ALLDAYS Light** 8153 Invention 8.5 140 ALWAYS Alldays*** 7.7 140 Invention 8 140*Commerically available from Kao Corp. **Commercially available fromKimberley Clark Corp. ***Commercially available from Procter & GambleCompany.

1. An absorbent article comprising in sequence a liquid permeable cover,an absorbent core, and a barrier, wherein the absorbent core comprisesat least two absorbent layers having different Gurley Stiffnesses,wherein a first absorbent layer proximal the liquid permeable cover hasa Gurley Stiffness of less than 50 milligrams and a second absorbentlayer proximal the barrier has a Gurley Stiffness of greater than 120milligrams, wherein one of the two absorbent layers is adjacent saidcover and one of the two absorbent layers is adjacent said barrier, saidlayer adjacent said cover is made of 50% to 65% pulp, the remainderbeing a combination of polyethylene/polypropylene bi-component fibersand polyethylene/polyester bi-component fibers, and said layer adjacentsaid banier is made of less than about 50% pulp, the remainder being acombination of polyethylene/polypropylene bi-component tibers andpolyethylene/polyester bi-component fibers.
 2. The absorbent article ofclaim 1, wherein the Bunching Resistance is at about 250 g to about 360g.
 3. The absorbent article of claim 1, wherein the absorbent corecomprises at least two absorbent layers having different GurleyStiffnesses.
 4. The absorbent article of claim 1, wherein the absorbentcore comprises one absorbent layer having a Gurley Stiffness that variesalong its length or width.
 5. The absorbent article of claim 1, whereinthe absorbent core comprises superabsorbent polymer.
 6. The absorbentarticle of claim 1, having a caliper of less than about 0.2 inches, alength of less than about 8 inches, and a width of less than about 4inches.
 7. The absorbent article of claim 6, wherein the absorbent corecomprises superabsorbent polymer.